Table saw

ABSTRACT

Persons skilled in the art may recognize other additions or alternatives to the means disclosed herein. However, all these additions and/or alterations are considered to be equivalents of the present invention.

FIELD OF THE INVENTION

This invention relates generally to a table saw and more specifically toconstruction techniques for manufacturing table saws.

BACKGROUND OF THE INVENTION

Typical portable table saws have a table, a base supporting the table, asaw assembly attached to the table and/or the base. The base istypically made of metal or plastic. Bases made of metal are typicallyheavy and relatively flexible, as they consist mostly of metal paneling.Bases made of plastic on the other hand could break when the table sawis dropped.

SUMMARY OF THE INVENTION

In accordance with the present invention, an improved table saw isemployed. The table saw has a base assembly, a table assembly supportedby the base assembly, a saw assembly supported by at least one of thetable assembly and the base assembly, the saw assembly including a sawblade extending through the table assembly, wherein the base assemblycomprises at least one tube connected to the table assembly.

Additional features and benefits of the present invention are described,and will be apparent from, the accompanying drawings and the detaileddescription below.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate preferred embodiments of theinvention according to the practical application of the principlesthereof, and in which:

FIG. 1 illustrates a table saw according to the invention;

FIG. 2 is a partial cross-sectional view illustrating a first method ofconnecting a tube to the table;

FIG. 3 is a partial cross-sectional view illustrating a second method ofconnecting a tube to the table;

FIG. 4 is a partial cross-sectional view illustrating an adjustable footassembly;

FIGS. 5A-5B illustrate the arrangement of controls relative to the baseassembly, where FIGS. 5A-5B are front and left views of the table saw,respectively;

FIG. 6 is a cross-sectional view illustrating a rail assembly of thetable saw;

FIG. 7 is a perspective view of a second embodiment of the table sawaccording to the invention;

FIG. 8 is a perspective view of a third embodiment of the table sawaccording to the invention;

FIG. 9 is a perspective view of a fourth embodiment of the table sawaccording to the invention;

FIG. 10 illustrates an assembly for storing a pushstick; and

FIG. 11 is a top plan view of the pushstick storing assembly of FIG. 10.

DETAILED DESCRIPTION

The invention is now described with reference to the accompanyingfigures, wherein like numerals designate like parts. Referring to FIG.1, a table saw 100 may include a base assembly 10, a table assembly 11supported by base assembly 10, and a saw assembly (not shown) supportedby the table assembly 11. Persons skilled in the art will recognize thatthe construction of the saw assembly is well known and can be found inU.S. Pat. Nos. 5,875,698, 6,009,782, and 6,907,807, all of which arehereby incorporated by reference.

The saw assembly may include a blade 31, extending through tableassembly 11.

Base assembly 11 may include at least one tube 21 attached to tableassembly 10. Tube 21 may be made of a composite material, such as carbonfiber or fiber glass, extruded metal, such as aluminum, steel tubing ormolded plastic. Persons skilled in the art will recognize plastic tubingmay be molded via gas-assist, injection molded, etc.

Preferably, base assembly 10 has two substantially U-shaped tubes 21connected to table assembly 11. Each U-shaped tube 21 has an uppercross-bar 21CC connecting two legs of the tube 21. Cross-bars 21CB maybe disposed between and connect the two U-shaped tubes 21. Cross-bars21CB and/or 21CC are preferably welded or bolted unto tubes 21.

Tubes 21 may be bolted directly unto table assembly 21. Alternatively, aflexible gasket 21R may be disposed between table assembly 11 and tube21. Referring to FIG. 2, a substantially annular gasket 21R may bedisposed between table assembly 11 and tube 21. A bolt 21B may extendthrough table assembly 11, gasket 21R and tube 21, and threadinglyengage nut 21N. Preferably, bolt 21B is inserted through a countersunkhole on table assembly 11 so that the bolt head will lie flush with orunderneath the table workpiece support plane 11WP.

Another method of connecting tube 21 to table assembly 11 is shown inFIG. 3, where like numerals refer to like parts. Rather than extendingthrough table assembly 11, bolt 21B may extend through a washer 21W andgasket 21R, and into tube 21. Tube 21 may have threaded area 21Nintegrated within or snapped unto tube 21 threadingly engaging bolt 21B.The assembly is then preferably held in place via a plate 21Psandwiching gasket 21R between plate 21P and table assembly 11. Plate21P may be bolted unto bosses 11B via bolts 21PB.

Persons skilled in the art shall recognize that it may be desirable toensure that gasket 21R is flexible in order to isolate shocks betweenthe table assembly 11 and base assembly 10. Gasket 21R is preferablymade of thermoplastic rubber, having a hardness of about 70 to about 80Shore A. Preferably the hardness of gasket 21R is about 75 Shore A.

Tubes 21 may have adjustable feet assemblies 23. Persons skilled in theart will recognize that providing adjustable feet assemblies 23 willallow a user to adjust table saw 100 so that table assembly 11 issubstantially horizontal.

Referring to FIG. 4, foot assembly 23 preferably includes a foot 23F.Foot 23F is preferably made of rubber, such as thermoplastic rubber, oranother flexible material. A bolt 23B may extend through foot 23F, awasher 23W and tube 21, and threadingly engage nuts 23N disposed on bothsides of tube 21. A user would adjust the foot assembly by rotating bolt23B and nuts 23N until the desired position is obtained.

Referring to FIGS. 1 and 5, panels 22 may be disposed on tube(s) 21.Panels 22 may be made of metal or plastic. A front panel 22 may supportan on/off switch 32, a height adjustment crank 33 and a bevel lock crank34. Preferably, the front tube 21 defines a front plane RP. Personsskilled in the art will recognize that it is desirable to shape thefront tube 21 and front panel 22 so that the on/off switch 32, theheight adjustment crank 33 and/or the bevel lock crank 34 do not extendbeyond front plane RP.

Similarly, a side panel 22 may support a cord wrap 36 or a wrench (notshown). Preferably, the tubes 21 define a side plane RR. Persons skilledin the art will recognize that it is desirable to shape the tubes 21 andside panel 22 so that the cord wrap 36 and/or a wrench do not extendbeyond the side plane RR.

Referring to FIGS. 5A-5B, foot assemblies 23 preferably define asubstantially horizontal plane HP. It is desirable that the center ofgravity CG is disposed between the foot assemblies 23.

Tubes 21 may have protrusions 21P extending substantially sidewardly.Table assembly 11 may have protrusions 11P extending substantiallysidewardly. Preferably protrusions 21P and table assembly 11 and/orprotrusions 11P define a substantially vertical plane VP, which may besubstantially perpendicular to horizontal plane HP.

Center of gravity CG is preferably disposed between protrusions 21P andtable assembly 11 and/or protrusions 11P. This would allow a user tostably dispose table saw 100 on its side, so that protrusions 21P andtable assembly 11 and/or protrusions 11P are resting on the floor orother substantially horizontal surface.

Another embodiment of base assembly 10 is shown in FIG. 7, where likenumerals refer to like parts. In this embodiment tubes 21 connect tableassembly 11 to a molded base 40. Preferably, base 40 is blow-molded froman impact-resistant plastic material. Persons skilled in the art arereferred to US Published Application Nos. 20050024021, 2005008301,20050083639, 20050264260 and 20050285560, which are fully incorporatedby reference, for information on how base 40 is formed and how tubes 21may be connected to base 40. Preferably base 40 has a floor 41.

Another embodiment of base assembly 10 is shown in FIG. 8, where likenumerals refer to like parts. In this embodiment, table assembly 11includes panels 11PP supporting the saw assembly, the on/off switch 32,the height adjustment crank 33 and/or the bevel lock crank 34. One ormore tubes 21 may be disposed underneath panels 11PP to support tablesaw 100. Preferably, tube(s) 21 are bolted unto panels 11PP.

Feet 43 may be bolted unto tube(s) 21. Feet 43 may be made of rubber,thermoplastic rubber or other flexible materials.

Tube(s) 21S may also be bolted to the side of panels 11PP. Personsskilled in the art will recognize that tube(s) 21S may be shaped so thatthey can act as workpiece supports. Accordingly, it is preferable thatthe top surfaces of tube(s) 21S be substantially coplanar with or belowworkpiece support plane 11WP. Persons skilled in the art will recognizethat tube(s) 21S may also be shaped so that they can support the tablesaw 100 when disposed on its side.

At least one panel 11PP preferably has a hole 11H, allowing the user touse tube 21 as a handle. Persons skilled in the art will recognize thattube(s) 21S can also be used as handles.

Another embodiment of base assembly 10 is shown in FIG. 9, where likenumerals refer to like parts. In this embodiment, vertical andhorizontal tubes 21 are connected to each other via joints 44. Joints 44may be injection molded. Preferably joints 44 have a flexible componentso the joints 44 can absorb shock, etc.

Referring to FIG. 1, table saw 100 preferably has a front rail assembly50 attached to a front side of table assembly 11, a rear rail assembly50 attached to a rear side of table assembly 11, the rail assemblies 50supporting a fence assembly 60. Persons skilled in the art are referredto U.S. Pat. No. 5,722,308, which is fully incorporated by reference,for information on the construction of rail assembly 50 and fenceassembly 60.

Referring to FIGS. 1 and 6, each rail assembly 50 preferably includes afixed rail assembly 51 bolted unto table assembly 11 via a bolt 51B.Rail assembly 51 may include a fixed rail 51R, which is preferably madeof extruded aluminum. Fixed rail 51R may have an overmolded portion 510.

A sliding rail 52 may be slidingly disposed on each fixed rail assembly51. Sliding rail 52 is preferably made of extruded aluminum. Slidingrail 52 preferably has a slot 52S and a channel 52C disposed adjacent tothe slot 52S.

A boss 54 may extend through slot 52S and threadingly engage a nut 54Ndisposed in channel 52C. This allows a user to move boss 54 along slot52S. Since fence assembly 60 has a mount 61 which is disposed on boss54, the user can thus adjust the position of the fence assembly 60relative to the sliding rail 52 and/or adjust the parallelism of fenceassembly 60 relative to blade 31.

Each sliding rail 52 may have a rack 53. A shaft 55S preferably extendsunderneath table assembly 11. Shaft 55S has two pinions 55P fixedlydisposed thereon meshing with racks 53. Shaft 55S and pinions 55P can berotated via a knob 55K. With such arrangement, when the user rotatesknob 55K, both sliding rails 52 will move an equal distance, maintainingfence assembly 60 parallel to blade 31.

Persons skilled in the art should recognize that fence assembly 60 has alatch (not shown) that engages slot 52S.

Referring to FIGS. 10-11, a pushstick 70 may be attached to a panel 22for storage. Panel 22 preferably has at least two holders 22H extendingfrom the panel 22. Each holder 22H preferably has a flange 22HF and apost 22HH connecting the flange 22HF to the panel 22. Preferably, theposts 22HH are disposed at a distance X.

The pushstick 70 preferably has at least two slots 71. Slots 71 aredisposed on pushstick 70 at about the same distance as distance X. Slots71 are at least as long as the flanges 22HF. Slots 71 preferably have awide area 71W and an adjacent narrow area 71N. The user can thus insertthe holders 22H through slots 71, then move the pushstick 70 so thatposts 22HH move through the wide area 71W into the narrow area 71N.Preferably, narrow area 71N is shaped so that friction is createdbetween narrow area 71N and post 22HH, thus limiting the movement ofpushstick 70 along panel 22. The flanges 22HF preferably limit themovement of pushstick 70 away from panel 22.

Ribs 22HR may be disposed between posts 22HH and panel 22 in order tostrengthen posts 22HH.

1-14. (canceled)
 15. A table saw comprising: a base assembly; a tableassembly supported by the base assembly; a saw assembly supported by atleast one of the table assembly and the base assembly, the saw assemblyincluding a saw blade extending through the table assembly; a frontfixed rail attached to the table assembly; a front sliding railslidingly disposed on the front fixed rail; and a fence assembly mountedon the front sliding rail; wherein the fence assembly is mounted on afirst boss movably attached to the front sliding rail.
 16. The table sawof claim 15, further comprising: a rear fixed rail attached to the tableassembly; and a rear sliding rail slidingly disposed on the front fixedrail; wherein the fence assembly is mounted on a second boss movablyattached to the rear sliding rail.
 17. The table saw of claim 16,wherein the front and rear sliding rails have first and second racksdisposed respectively thereon.
 18. The table saw of claim 17, furthercomprising: a shaft disposed underneath the table assembly; first andsecond pinions disposed on the shaft and meshingly engaging the firstand second racks, respectively; and a knob disposed on the shaft forrotating the shaft and first and second pinions.
 19. The table saw ofclaim 15, wherein the front fixed rail comprises an extruded rail and aportion overmolded on the extruded rail.
 20. The table saw of claim 15,wherein the front sliding rail has a slot extending along substantiallythe length of the front sliding rail, the first boss extending throughthe slot. 21-25. (canceled)